Modular heater systems

ABSTRACT

A heat trace assembly is provided that includes a heat trace section, an insulation jacket surrounding the heat trace section, and a plurality of standoffs disposed between the heat trace section and the insulation jacket. A corresponding plurality of passageways are formed between the heat trace section and the insulation jacket and between the plurality of standoffs. The standoffs can be a part of the insulation jacket and/or the heat trace section, and the standoffs can furthermore be integrally formed with or separately attached to the insulation jacket and/or the heat trace section.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 11/435,073, titled “Modular Heater Systems,” filed on May 16,2006, which is a continuation-in-part of U.S. patent application Ser.No. 11/199,832, titled “Modular Heater Systems,” filed on Aug. 9, 2005now U.S. Pat. No. 7,626,146. The disclosures of the above applicationsare incorporated herein by reference.

FIELD

The present disclosure relates generally to electric heaters for use inpipelines, and more particularly to electric heaters for use in gaslinesand pumplines such as, by way of example, semiconductor processingsystems.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

The supply of fluids such as oil, gas, and water, among others, from asupply, e.g., an oil well or a water reservoir, requires transfer ofsuch fluids by conduits or the like. Maintaining a free or unrestrictedflow of the fluids within the conduits is often necessary, in additionto maintaining the fluid at or above a certain temperature. Presently,an electric heater in the form of a cable or a tape, known in the art asa “heat trace,” is commonly used around the conduits to provide heat tothe conduits and thus to the fluids. Additionally, the conduits and theheat traces are sometimes surrounded by a thermal insulation jacket toreduce heat loss to the surrounding environment.

Heat trace cables are a popular means for heating such fluid conduitsdue to their relative simplicity and low cost. Generally, heat tracecables are disposed along the length of the conduits or wrapped aroundthe conduits and are fastened at regular intervals with bands, retainingstraps or any other suitable fasteners, as shown in U.S. Pat. No.5,294,780 to Montierth et al., U.S. Pat. No. 5,086,836 to Barth et al.,U.S. Pat. No. 4,791,277 to Montierth et al., U.S. Pat. No. 4,152,577 toLeavines, U.S. Pat. No. 4,123,837 to Horner, U.S. Pat. No. 3,971,416 toJohnson, and U.S. Pat. Reissue No. 29,332 to Bilbro. Fastening heattrace cables to the pipe or conduit has proven to be time consuming andburdensome, particularly for replacement of utility lines and continuousmanufacturing processes, among others, where time is of the essence.

To expedite the replacement of utility lines, U.S. Pat. No. 6,792,200proposes a pre-fabricated heat-traced pipe, wherein a pipe to be heated,a heat trace, and a connector for electrically connecting the heat traceto a power source are cured and integrally formed beforehand andinventoried before a need for replacing an old pipe arises. While thisprefabricated pipe saves some time with respect to replacement ofutility lines, it requires a custom-made heat-traced pipe, therebyincreasing undesirable inventory space and manufacturing and maintenancecosts.

SUMMARY

In one preferred form, a heat trace assembly is provided that comprisesa heat trace section, an insulation jacket surrounding the heat tracesection, and a plurality of standoffs disposed between the heat tracesection and the insulation jacket. A corresponding plurality ofpassageways are formed between the heat trace section and the insulationjacket and between the plurality of standoffs. The standoffs asdisclosed herein may be integrally formed, separately attached, and maytake on a variety of geometrical configurations.

In another form, an insulation jacket for use in a heating system isprovided that comprises a plurality of standoffs extending from an innersurface of the insulation jacket and inwardly towards a heater, whereina plurality of passageways are formed between the heater and theinsulation jacket and between the plurality of standoffs.

In yet another form, a heat trace section for use in a heating system isprovided that comprises a plurality of standoffs extending from an outersurface of the heat trace section and outwardly towards an insulationjacket, wherein a plurality of passageways are formed between the heattrace section and the insulation jacket and between the plurality ofstandoffs.

Further areas of applicability will become apparent from the descriptionprovided herein. It should be understood that the description andspecific examples are intended for purposes of illustration only and arenot intended to limit the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a schematic view showing one of the applications of a modularheat trace assembly to heated semiconductor gaslines and pumplines;

FIG. 2 is a perspective view of a prior art heat trace cable disposedaround a gasline or pumpline;

FIG. 3 is a perspective cutaway view of a prior art heat trace cable;

FIG. 4 is a cross-sectional view, taken along line 3-3, of the prior artheat trace cable of FIG. 3;

FIG. 5 is a perspective view of a modular heat trace assembly secured toa conduit system in accordance with a first embodiment of the presentdisclosure;

FIG. 6 is an exploded perspective view of the modular heat traceassembly of FIG. 5 in accordance with the teachings of the presentdisclosure;

FIG. 7 is a perspective view of a heat trace section of FIGS. 5 and 6constructed in accordance with the teachings of the present disclosure;

FIG. 8 is an end view of the heat trace section of FIG. 7 in accordancewith the teachings of the present disclosure;

FIG. 9 is a perspective view of a connector of FIGS. 5 and 6 inaccordance with the teachings of the present disclosure;

FIG. 10 is a top view of the connector of FIG. 9 in accordance with theteachings of the present disclosure;

FIG. 11 a is a perspective view of a connector in accordance with oneembodiment constructed in accordance with the principles of the presentdisclosure;

FIG. 11 b is a perspective view of a connector in accordance withanother embodiment constructed in accordance with the principles of thepresent disclosure;

FIG. 11 c is a perspective view of a connector in accordance with yetanother embodiment constructed in accordance with the principles of thepresent disclosure;

FIG. 12 is a perspective view of a heat trace section constructed inaccordance with a second embodiment of the present disclosure;

FIG. 13 is an end view of the heat trace section of FIG. 12 inaccordance with the teachings of the present disclosure;

FIG. 14 is a top view of a bussing adapter constructed in accordancewith the teachings of the present disclosure

FIG. 15 is a perspective view of a heat trace junction constructed inaccordance with a third embodiment of the present disclosure;

FIG. 16 is a perspective view of an alternate form of the heat tracejunction of FIG. 15 configured for an elbow junction of a conduit systemand constructed in accordance with the teachings of the presentdisclosure;

FIG. 17 is a perspective view of an alternate form of the heat tracejunction of FIG. 15 configured for a T-junction of a conduit system andconstructed in accordance with the teachings of the present disclosure;

FIG. 18 is a perspective view of heat trace sections with terminationstructures in accordance with a fourth embodiment of the presentdisclosure, the heat trace sections being in a disengaged state;

FIG. 19 is a side view of the heat trace sections of FIG. 18 inaccordance with the teachings of the present disclosure;

FIG. 20 is a perspective view of the heat trace sections of FIG. 18 inan engaged state in accordance with the teachings of the presentdisclosure;

FIGS. 21 is a side view of the heat trace sections of FIG. 20 inaccordance with the teachings of the present disclosure;

FIG. 22 is a side view of an alternate form of connecting the heat tracesections of FIGS. 18-21 and constructed in accordance with the teachingsof the present disclosure;

FIG. 23 is a perspective cutaway view of another embodiment of a heaterconstruction, a z-directional heater, in accordance with the teachingsof the present disclosure;

FIG. 24 is a perspective view of a thermal insulation jacket for aheated conduit constructed in accordance with the teachings of thepresent disclosure;

FIG. 25 is an end view of a thermal insulation jacket with an alternatepocket configuration and constructed in accordance with the teachings ofthe present disclosure;

FIG. 26 is a perspective view of another form of a thermal insulationjacket for a heated conduit constructed in accordance with the teachingsof the present disclosure;

FIG. 27 is a perspective view of a still another form of a thermalinsulation jacket for a heated conduit constructed in accordance withthe teachings of the present disclosure;

FIG. 28 is a perspective view of yet another form of a thermalinsulation jacket for a heated conduit constructed in accordance withthe teachings of the present disclosure;

FIG. 29 is a perspective view of another embodiment of a modular heattrace assembly constructed in accordance with the teachings of thepresent disclosure;

FIG. 30 is another perspective view of the modular heat trace assemblyof FIG. 29 in accordance with the teachings of the present disclosure;

FIG. 31 is an exploded perspective view of the modular heat traceassembly of FIG. 30 in accordance with the teachings of the presentdisclosure;

FIG. 32 is a perspective view of a heat trace section constructed inaccordance with the teachings of the present disclosure;

FIG. 33 is an exploded perspective view of the heat trace section inaccordance with the teachings of the present disclosure;

FIG. 34 is a perspective view of a heat trace section comprising finsand constructed in accordance with the teachings of the presentdisclosure;

FIG. 35 is an end view of the heat trace section comprising fins inaccordance with the teachings of the present disclosure;

FIG. 36 is an end view of the heat trace section comprising fins anddisposed within an insulation jacket in accordance with the teachings ofthe present disclosure;

FIG. 37 is a perspective view of an insulation jacket constructed inaccordance with the teachings of the present disclosure;

FIG. 38 is an end view of the insulation jacket in accordance with theteachings of the present disclosure;

FIG. 39 is a perspective view of a heat trace section engaging aterminating member and constructed in accordance with the teachings ofthe present disclosure;

FIG. 40 is a perspective view of the terminating member in accordancewith the teachings of the present disclosure;

FIG. 41 is a front perspective view of a housing body of the terminatingmember constructed in accordance with the teachings of the presentdisclosure;

FIG. 42 is a rear perspective view of the housing body in accordancewith the teachings of the present disclosure;

FIG. 43 is a front perspective view of an end cap of the terminatingmember constructed in accordance with the teachings of the presentdisclosure;

FIG. 44 is an back end view of the housing body in accordance with theteachings of the present disclosure;

FIG. 45 is an back end view of the housing body with internal electricalconnections and constructed in accordance with the teachings of thepresent disclosure;

FIG. 46 is a front end view of the housing body illustrating portions ofthe electrical connections and constructed in accordance with theteachings of the present disclosure;

FIG. 47 is a front end view of the modular heat trace assemblyconstructed in accordance with the teachings of the present disclosure;

FIG. 48 is a front perspective view of the connector assemblyconstructed in accordance with the teachings of the present disclosure;

FIG. 49 is a rear perspective view of the connector assembly inaccordance with the teachings of the present disclosure;

FIG. 50 is an exploded perspective view of the connector assembly inaccordance with the teachings of the present disclosure;

FIG. 51 is a partial perspective view of a fitting heater assemblyconstructed in accordance with the teachings of the present disclosure;

FIG. 52 is another partial perspective view of the fitting heaterassembly constructed in accordance with the teachings of the presentdisclosure;

FIG. 53 is a perspective view of an alternate embodiment of an outercasing having a snap feature and constructed in accordance with theteachings of the present disclosure;

FIG. 54 is a perspective view of a cover engaged with a shell member andconstructed in accordance with the teachings of the present disclosure;

FIG. 55 is a side view of the cover engaged with the shell member inaccordance with the teachings of the present disclosure;

FIG. 56 is a perspective view of another form of a heat trace assemblyconstructed in accordance with the teachings of the present disclosure;

FIG. 57 is an end view of the heat trace assembly in accordance with theteachings of the present disclosure;

FIG. 58 is a perspective view of the heat trace assembly illustratingrotatable segments of an insulation jacket in accordance with theteachings of the present disclosure;

FIG. 59 a is a perspective view of an alternate form of standoffsconstructed in accordance with the teachings of the present disclosure;

FIG. 59 b is a perspective view of another alternate form of standoffsconstructed in accordance with the teachings of the present disclosure;

FIG. 59 c is a perspective view of another alternate form of standoffsconstructed in accordance with the teachings of the present disclosure;

FIG. 60 is a perspective view of another form of a heat trace assemblyutilizing a carrier and constructed in accordance with the teachings ofthe present disclosure;

FIG. 61 is an exploded perspective view of the heat trace assembly withthe carrier in accordance with the teachings of the present disclosure;

FIG. 62 a is an end view of an alternate form of a carrier constructedin accordance with the teachings of the present disclosure;

FIG. 62 b is an end view of another alternate form of a carrierconstructed in accordance with the teachings of the present disclosure;

FIG. 63 is a perspective view of an alternate form of a heat tracesection having a stripped end portion and constructed in accordance withthe teachings of the present disclosure;

FIG. 64 is a perspective view of a terminating member secured to thestripped end portion of the heat trace section in accordance with theteachings of the present disclosure;

FIG. 65 is a perspective view of the terminating member secured to thestripped end portion of the heat trace section, illustrating electricalcomponents therein, along with an end cap, in accordance with theteachings of the present disclosure;

FIG. 66 is a perspective view of another alternate form of a heat tracesection having a stripped end portion and constructed in accordance withthe teachings of the present disclosure;

FIG. 67 is a perspective view of an end shield secured to the strippedend portion of the heat trace section in accordance with the teachingsof the present disclosure;

FIG. 68 is a perspective view of a terminating member secured againstthe end shield in accordance with the teachings of the presentdisclosure;

FIG. 69 is a perspective view of the terminating member secured to thestripped end portion of the heat trace section, illustrating electricalcomponents therein, along with an end cap, in accordance with theteachings of the present disclosure;

FIG. 70 is an end view of an alternate form of a heat trace sectionhaving multiple dielectric covers and constructed in accordance with theteachings of the present disclosure;

FIG. 71 is an end view of another alternate form of a heat trace sectionhaving multiple dielectric covers and constructed in accordance with theteachings of the present disclosure;

FIG. 72 is an end view of an alternate heat trace section having areduced area and constructed in accordance with the teachings of thepresent disclosure;

FIG. 73 is a perspective view of an alternate form of a fitting adapterconstructed in accordance with the teachings of the present disclosure;

FIG. 74 is an exploded perspective view of the fitting adapter and anadjacent fitting in accordance with the teachings of the presentdisclosure;

FIG. 75 is a perspective view of an alternate form of an insulationjacket constructed in accordance with the teachings of the presentdisclosure; and

FIG. 76 is an end view of the insulation jacket in accordance with theteachings of the present disclosure.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is notintended to limit the present disclosure, application, or uses.

The structure of a heater in accordance with the present disclosure isnow described in greater detail. At the outset, it should be understoodthat the word “conduit” as used throughout this specification includes,without limitation, tubes, pipes, and other enclosed or partiallyenclosed members for the transfer of fluids or other materials such aspowders or slurries. The materials carried by the conduits describedherein includes solids, liquids, and gases and may include, by way ofexample, fluids that are transferred within a semiconductor processingapparatus. The following description of the preferred embodiments withreference to such a semiconductor processing apparatus is merelyexemplary in nature and is in no way intended to limit the disclosure,its application, or uses. Accordingly, the teachings of the presentdisclosure are not limited to a semiconductor processing apparatus andcan be applied to any system of conduits while remaining within thescope of the present disclosure.

Referring to FIG. 1, a semiconductor processing system 10 isillustrated, which generally includes a heated gasline 12 that extendsfrom a remote gas delivery system to a process tool, and a heatedpumpline 14 that extends from the process tool, through a plurality ofcomponents as shown, and to a scrubber. During operation, both thegasline 12 and the pumpline 14 must be heated according to specificprocessing requirements, which has typically been accomplished with heattrace cables 16 as shown in FIG. 2. The heat trace cables 16 are placedor wrapped along the length of the gasline 12 or pumpline 14 as shown,and are secured to the gasline 12 or pumpline 14 using a glass tape 18or other securing means. Additionally, insulation 20 is often placedaround the heat trace cables 16 to reduce heat loss to the outsideenvironment. The insulation 20 is typically wrapped around the heattrace cables 16 and secured in place by separate pieces of tape or tiesaround the gasline 12 or pumpline 14.

Referring to FIGS. 3 and 4, the construction and materials of the heattrace cables 16 are illustrated and described in greater detail. Theheat trace cable 16 typically includes a pair of bus-conductors 22,which are surrounded by a semiconductive polymer material 24 thatfunctions as a heating element. A dielectric or insulator material 26surrounds the semiconductive polymer material 24, which may optionallybe surrounded by a metal braid material 28 as shown for additionalfunctionality such as a ground plane. Further, an outer jacket 30surrounds the metal braid material 28 to protect the overall assembly,and the outer jacket 30 is typically an insulating material such as athermoplastic.

Although relatively lower cost than other heater systems, heat tracecables 16 must be cut to length in the field and spliced into anappropriate connector or terminal, which is often time consuming andcumbersome. Additionally, heat trace cables 16 are not as capable asother heating systems in providing a relatively uniform heating profilealong the length of a conduit due to the limited area of coverage andthe relatively crude means by which they are secured to the conduit.Heat trace cables 16 provide only casual contact with the conduit due totheir stiffness and difficulty in forming to the shape of the conduit.

With reference now to FIGS. 5 through 8, a modular heat trace assemblyadapted for use in a semiconductor processing system 10 in accordancewith a first embodiment of the present disclosure is illustrated andgenerally indicated by reference numeral 50. The modular heat traceassembly 50 comprises heat trace sections 52 for contacting and heatinga conduit 13 of the semiconductor processing system 10. The modular heattrace assembly 50 also comprises connectors 54 for securing adjacentheat trace sections 52 and for securing the modular heat trace assembly50 to components of the semiconductor processing system 10 as describedin greater detail below.

The heat trace sections 52 are preferably formed as an elongated shapeas shown and include a curved portion 56 and a pair of opposing lockingedges 58 extending in a longitudinal direction of the curved portion 56.The curved portion 56 has an inner surface 60 defining an open channel62 for placement around the conduit 13. The inner surface 60 ispreferably complementary to an outer surface of the conduit 13 to allowfor securing the heat trace section 52 to the conduit 13. The curvedportion 56 preferably surrounds at least a half of the entire outersurface of the conduit 13 to provide more uniform heat transfer from theheat trace section 52 to the conduit 13 and to allow for self-locking ofthe heat trace section 52 around the conduit 13 by the locking edges 58.

As shown, the locking edges 58 are spaced apart in a directiontransverse to the longitudinal axis of the curved portion 56 and are soconfigured as to facilitate the mounting of the heat trace sections 52to the conduit 13. Since the heat trace material is flexible, when thechannel 62 of the heat trace section 52 is placed around the conduit 13,the locking edges 58 can be deflected outwardly and are then biasedagainst the conduit 13 when released to secure the heat trace section 52to the conduit 13.

As further shown, a pair of conductors 64 are provided within the heattrace section 52, preferably along the locking edges 58 as shown,wherein the conductors 64 extend outwardly from opposite ends 66 and 68.The conductors 64 are configured for connection to a power source (notshown) for providing heat along the heat trace section 52. Theconductors 64 are also adapted, as described in greater detail below,for connection to an adjacent heat trace section 52 or to an adjacentconnector 54. Although not illustrated in FIGS. 5 through 8, it shouldbe understood that the heat trace section 52 comprises thesemiconductive polymer material, a dielectric or insulator materialsurrounding the semiconductive polymer material, and may also compriseoptional materials for a ground plane and an outer jacket as previouslydescribed. These separate materials are not illustrated with the heattrace section 52 for purposes of clarity.

The heat trace sections 52 are preferably preformed in sizescorresponding to different sizes, or outside diameters for example, ofthe conduit 13. The heat trace sections 52 are also capable of being cutto length, according to a desired length for a particular section ofconduit 13. Preferably, the heat trace sections 52 are provided instandard sizes and lengths for ease of repair and replacement within aconduit system such as the semiconductor processing system 10 as shown.Accordingly, the modular construction of the heater system according tothe teachings of the present disclosure facilitates a relatively lowcost heater system that is easily adapted to a conduit system.

Referring now to FIGS. 9 through 11 c in conjunction with FIGS. 5 and 6,the connector 54 is provided proximate at least one of the opposite ends66 or 68 of the heat trace section 52 to secure the heat trace section52 to an adjacent heat trace section 52 between or across a fitting 70of the conduit system 10. Preferably, the connector 54 is formed to theshape of the fitting for ease of installation and removal. Additionally,a mating cover 72 is provided to cover the connector 54 proximate thefitting, which is also formed to the shape of the fitting.

The heat trace section 52 and the connector 54 define mating features toallow for a quick engagement and disengagement between the heat tracesection 52 and the connector 54. In this illustrative embodiment, theconnector 54 is provided with a pair of corresponding grooves 58 forreceiving the conductors 64, which are typically in the form of pins, orexposed wires a result of stripping, in a heat trace type heater, asdescribed in greater detail below.

The connector 54 may comprise one of a plurality of forms for electricalconnection and heat transfer in accordance with the teachings of thepresent disclosure. In a first form shown in FIG. 11 a, the connector 54comprises an insulative material and includes electrical connectorelements 74 disposed within the grooves 58. The electrical connectorelements 74 are generally in the form of a socket and are adapted toreceive the conductors 64 as shown. The electrical connector elements 74may be sized for an interference fit, or alternately, may be crimpedonto the conductors 64 as necessary. Alternatively, the electricalconnector elements 74 may comprise a squeeze connector, which is alsoknown as an insulation displacement or piercing connector, that includesan electrical contact that is moved by a flexible cover or housing tocontact the conductors 64 through their surrounding materials, e.g.,insulating material, semiconductive polymer material metal braidmaterial. An exemplary squeeze connector is illustrated in U.S. Pat. No.4,861,278, and a wide variety of such connectors are commerciallyavailable from numerous sources and are not illustrated herein forpurposes of brevity. Accordingly, it should be understood that a varietyof electrical connectors may be employed while remaining within thescope of the present disclosure. It should also be understood thatelectrical connection between the electrical connector elements 74across the connector 54, as indicated by the dashed line 75, may also beemployed in order to provide electrical continuity across the connector54, using a variety of electrical connection approaches while remainingwithin the scope of the present disclosure.

In a second form as shown in FIG. 11 b, the connector 54 comprises aninsulative material with the electrical connector elements 74 as shownabove and also comprises a pre-formed heat trace section 76 disposedwithin the body of the connector 54. The heat trace section 76 thusprovides the requisite heat to the fitting 70 of the conduit system 10and is constructed in accordance with the teachings of the presentdisclosure as described above.

In a third form as shown in FIG. 11 c, the connector 54 comprises aninsulative material with the pre-formed heat trace section 76 and notthe electrical connector elements 74. In this form, the conductors 64extend from the connector 54 as shown and are subsequently attached toanother connector or terminal for electrical connection to a powersource (not shown). Alternately, the connector 54, in each of the formsillustrated herein, may also include a discrete temperature sensor (notshown), or inherent temperature sensing capability using TCR(temperature coefficient of resistance) materials, for improvedtemperature control of the heater system.

In yet another form, a heat transfer compound such as a silicone ornon-silicone based paste, or a sheet-type thermal gel, among others, isdisposed on one side of the connector 54, on one or more of the exposedsurfaces adjacent the conduit 13 for improved heat transfer.Accordingly, it should be understood that a variety of thermal interfacematerials may be employed both on the connector 54 and the heat tracesection 52 to improve or control heat transfer while remaining withinthe scope of the present disclosure.

It should be noted that while a pin and groove configuration is used forconnecting the heat trace section 52 to the connector 54, other featuresfor connecting the same can be used as long as the connector 54functions to secure the heat trace section 52 to an adjacent heat tracesection 52 and to provide electrical continuity across the connection.For example, such features may include, by way of example, screws, pegs,snaps, clips, and the like to align and/or secure the mating structure.Additionally, features other than mechanical elements may be employed,such as electromagnetic features, while remaining within the scope ofthe present disclosure.

It should also be noted that while the heat trace section 52 isdescribed in the first embodiment to have a curved portion 56, the heattrace section 52 is not limited to the shape and configuration asillustrated herein. The heat trace section 52 can be of any shape aslong as it can be properly secured to the conduit 13 and thus provideheat to the conduit 13. For example, the heat trace section 52 may havea rectangular shape for receiving a rectangular conduit. Though it ispreferred, it is not necessary to require that the heat trace section 52be in direct contact with the conduit 13 as shown and described hereinto achieve the purpose of heating the conduit 13. Moreover, multiplepieces of the heat trace section 52 may be employed around thecircumference of the conduit 13 rather than a single piece asillustrated herein. Such variations should be understood to be withinthe teachings and scope of the present disclosure.

Referring to FIGS. 12 and 13, a heat trace section in accordance with asecond embodiment of the present disclosure is generally indicated byreference numeral 100. The heat trace section 100 includes a pluralityof conductors 110 in order to facilitate a larger size conduit 13 and toprovide the requisite power to heat the conduit 13 and the fluidstherein. The conductors 110 extend outwardly from the opposing ends 112and 114 along the longitudinal axis of the heat trace section 100 forelectrical connection to a power source (not shown) and/or to anadjacent heat trace section 100 or to a connector 54.

In the illustrative embodiment, seven panels 102 are shown to define atubular channel 106 for receiving a conduit 13 therein. Two panels 102are not joined along one of their longitudinal sides 104 to form alongitudinal slit 108 as shown. The longitudinal slit 108 facilitatesthe mounting of the heat trace section 100 onto the conduit 13. Sincethe heat trace section 100 is made of a flexible material, by deflectingthe two panels 102 outwardly that define the longitudinal slit 108, theheat trace section 100 can be secured over the conduit 13, similar tothe heat trace section 52 as previously described.

As previously stated, the heat trace section 100 of this embodiment isparticularly suitable for a conduit having a larger size. The number ofpanels 102 thus depends on the size of the conduit 13 to be heated andis not limited to seven as shown in the illustrative embodiment of FIGS.12 and 13. It should be understood that any number of conductors 110 andcorresponding panels 102 may be employed according to the size andheating requirements of the conduit 13 while remaining within the scopeof the present disclosure.

Referring to FIG. 14, a bussing adapter that functions to adapt themulti-conductor embodiment of FIGS. 12 and 13 to a two-conductorconnector 54 as previously shown is illustrated and generally indicatedby reference numeral 150. As shown, the bussing adapter 150 ispreferably in the form of a ring that is disposed between the heat tracesection 100 and the connector 54. The bussing adapter 150 is preferablyan insulative material and includes a plurality of electrical connectorelements 152 (shown dashed) on one side, preferably in the form ofsockets, to receive the plurality of conductors 110 of the heat tracesection 100. On the opposite side, the bussing adapter 150 includes apair of conductors 154 that extend from the body of the bussing adapter150 to engage with the electrical connector elements 74 (shown dashed)of the connector 54. Inside the bussing adapter 150, the electricalconnector elements 74 are bussed (not shown) to each of the conductors154 to provide for electrical continuity.

Referring now to FIGS. 15 through 17, in accordance with a thirdembodiment of the present disclosure, a heat trace junction for use withintersections or joints of a conduit system 10 is provided and isgenerally indicated by reference numeral 200. As shown, the heat tracejunction 200 preferably defines a cross configuration having a pluralityof arms 204 extending from a base portion 202. Each of the arms 204 havean engaging end 206 provided with a pair of conductors 208 forconnecting to an adjacent power source (not shown) or an adjacent heattrace section or junction. Although only two conductors 208 are shown atthe engaging ends 206, it should be understood that a plurality ofconductors, i.e. more than two, may be employed according to specificpower requirements while remaining within the scope of the presentdisclosure. Additionally, the path of the conductors 208 may varyaccording to specific heating requirements, and it should be understoodthat paths other than those illustrated herein, e.g. traveling down oneor two arms 204 rather than all four as shown, should be construed asfalling within the teachings and the scope of the present disclosure.

The heat trace junction 200 can be formed into an appropriate shape tobe properly mounted to a junction of the conduit system 10. For example,the heat trace junction 200 can be formed into an elbow shape 210 asshown in FIG. 16 for use with an elbow junction of the conduit system 10(shown in FIG. 1). Alternately, the heat trace junction 200 can beformed into a T-shape 212 as shown in FIG. 17 for use with a T-junction(not shown) of the conduit system 10. As further shown, the conductors208 may comprise a variety of configurations as shown in FIGS. 16 and17, depending on the need for connecting the junctions to an adjacentheat trace section or to a connector.

Referring to FIGS. 18 through 21, a modular heat trace connectorassembly in accordance with a fourth embodiment of the presentdisclosure is generally indicated by numeral 300. The modular heat traceconnector assembly 300 comprises a first heat trace section 302, a firsttermination structure 304, a second heat trace section 306, and a secondtermination structure 308. Although the first heat trace section 302 andthe second heat trace section 306 are shown in FIGS. 18 through 21 todefine a relatively flat shape, it should be understood that therespective heat trace sections 302 and 306 can be of any geometricalshape such as the circular or cylindrical shape previously illustrated.Accordingly, the flat shape should not be construed as limiting thescope of the present disclosure.

The first heat trace section 302 and the second heat trace section 306each have an abutting end 310 and 312 and a distal end 314 and 316. Thetermination structures 304 and 308 are provided at the abutting ends 310and 312 and have mating features for being mechanically and electricallycoupled together. More specifically, the first termination structure 304has an upper engaging portion 318 and a lower engaging portion 320. Thesecond termination structure 308 also has a corresponding upper engagingportion 322 and a corresponding lower engaging portion 324. The upperengaging portion 318 of the first termination structure 304 defines apin configuration while the upper engaging portion 322 of the secondtermination structure 308 defines a socket configuration to facilitatethe engagement between the upper engaging portions 318 and 322. In onepreferred form, the upper engaging portion 318 of the first terminationstructure 304 includes a pair of pins 326. The upper engaging portion322 of the second termination structure 308 includes a correspondingpair of sockets 330 for receiving the pins 326 therein, thus providing amechanical and electrical connection. Preferably, the terminationstructures 304 and 308 are made of a nickel material, although othermaterials such as copper that provide sufficient electrical continuitymay also be employed while remaining within the scope of the presentdisclosure.

As further shown, the lower engaging portion 320 of the firsttermination structure 304 includes a pair of extensions 332 from whichthe pins 326 of the upper engaging portion 318 extend upwardly. Thelower engaging portion 324 of the second termination structure 308 alsoincludes a pair of extensions 334 from which the engaging arms 328 ofthe upper engaging portion 322 extend. The extensions 322 and 334 eachreceive therein a conductor 336 of the heat traces 302 and 306 forelectrical continuity.

Though not shown in the drawings, the distal ends 314 and 316 of thefirst heat trace section 302 and the second heat trace section 306 mayoptionally be provided with termination structures 304 or 308 to beconnected to additional sections of heat traces or to a connector.Alternatively, the distal ends 314 and 316 may be provided with suitableengaging means (not shown in the drawings) for being connected to apower source (not shown).

Referring to FIG. 22, an alternate connector for connecting heat tracesections 340 and 342 is illustrated and generally indicated by referencenumeral 344. The connector 344 generally defines a “U” configuration toconnect the conductors 346 as shown. The flexible conductors 346 areturned upwards as shown in order to engage the connector 344, whichdefines receiving holes (not shown) in one form of the presentdisclosure. The connector 344 may be press-fit, bonded, or welded ontothe conductors 346 in accordance with techniques as known in the art.Accordingly, the ends of heat trace section 340 and 342 having exposedconductors 346 are closer together than the previously illustratedembodiment, thus improving the uniformity of heat transfer along theheat trace sections.

The modular heat trace connector assembly 300 is thus configured toposition the pin and socket connection area away from the hot surface ofthe heat trace sections 302 and 306 in order to reduce thermal fatigueof the pins and sockets in high temperature applications.

Although the above-described modular heater assembly 50 has beenillustrated and detailed as having a construction similar to aconventional heat trace cable, it should be understood that other typesof heater construction besides a heat trace cable construction may alsobe employed while remaining within the scope of the present disclosure.A heater type such as a polymer heater or a layered film heater, amongothers, that is modular and can easily be replaced and repaired in aconduit system using the modular connectors and other embodiments asdescribed herein should be construed as being within the scope of thepresent disclosure.

With reference to FIG. 23, an embodiment of a z-directional heater inaccordance in the teachings of the present disclosure is illustrated andgenerally indicated by reference numeral 350. The z-directional heater350 comprises a pair of conductors 352, each of which are electricallyconnected to foil elements 354. A conductive polymer material 356 isdisposed between the foil elements 354 as shown, and an insulatingmaterial 358 surrounds the entire assembly. The z-directional heater 350is adapted for a modular construction as previously described, and withthe addition of the foil elements 354, the quality of the heat providedby the heater can be tailored to specific application requirements. Itshould be understood that the shape and configuration of thez-directional heater 350 is exemplary only and other shapes andadditional elements, such as those described herein, e.g., tubularshape, a ground plane element, may also be employed while remainingwithin the scope of the present disclosure. Moreover, elements 354 arenot limited to a foil material, and in alternate forms comprise a gridor screen material.

The z-directional heater 350 is preferably formed as a sheet of materialwith multiple conductors 352 and corresponding foil elements 354. Assuch, any size of z-directional heater 350 can be easily cut or removedfrom the sheet according to specific application requirements. Forexample, multiple sections of conductors 352 and foil elements 354, e.g.more than one set of each, can be removed across a width of the sheet,along with cutting the length of the conductors 352 and foil elements354 to the desired dimension(s).

Referring now to FIG. 24, a thermal insulation jacket for a heat-tracedconduit, or a heated conduit (not shown), is generally indicated byreference numeral 400. The thermal insulation jacket 400 preferablydefines a tubular insulation body 402, which has an outer wall 403 andan inner wall 404 defining a channel 406 for receiving a heated conduit,which may be a heat-traced conduit as previously described. The innerwall 404 defines a pocket 408 to house a conventional heat trace cable,as previously described, that is placed along the length of a conduit.Alternately, the pocket 408 may take any number of shapes, such as anarcuate pocket 410 as shown in FIG. 25, to accommodate the heat tracesection 52 as shown and described herein. Accordingly, the shape of thepocket 408 is designed to mirror or conform to the shape of the heattrace section, whatever that shape might be. Additionally, the thermalinsulation jacket 400 having pocket 408 can alternately be provided witha slit 412 so that the jacket 400 can be deformed and placed over aconduit rather than being slid along the length of the conduit.Moreover, the thermal insulation jacket 400 in the configurations asshown can serve to accurately position one or more heat trace sectionsagainst the conduit for the purpose of controlling the heat losses toatmosphere.

Referring to FIG. 26, another form of a thermal insulation jacket for aheated conduit is generally indicated by reference numeral 420. Thethermal insulation jacket 420 preferably defines a tubular insulationbody 422 defining an outer wall 423 and an inner wall 425. The tubularinsulation body 422 is formed with a plurality of air chambers 424extending longitudinally between the outer wall 423 and the inner wall425 as shown. The air chambers 424 thus provide an area to improve theuniformity of heat dissipation along the heat trace sections and toreduce heat losses through the thermal insulation jacket 420.

Referring to FIG. 27, another form of a thermal insulation jacket forheated conduit and having air chambers is generally indicated byreference numeral 430. The thermal insulation jacket 430 preferablydefines a tubular insulation body 432 having an outer wall 433 and aninner wall 435. As shown, the tubular insulation body 432 has aplurality of air pockets 434 formed into the inner wall 435 and arrangedin a somewhat random configuration along the longitudinal direction ofthe tubular insulation body 432. Accordingly, the air pockets 434 reduceheat losses through the thermal insulation jacket 430.

Referring to FIG. 28, still another form of a thermal insulation jacketfor a heated conduit is generally indicated by reference numeral 440.The thermal insulation jacket 440 defines a tubular insulation body 442,which has a longitudinal slit 444 defined by opposing longitudinal edges446 and 448. The opposing longitudinal edges 446 and 448 are spacedapart in a circumferential direction and are properly spaced to allowfor placement around a heated conduit. More specifically, the tubularinsulation body 442 is made of a flexible material, e.g., siliconerubber sheet or foam, neoprene, polyimide foam or tape, among manyothers, such that the longitudinal edges 446 and 448 are deflectedoutwardly and are then biased against the heated conduit.

As further shown, one of the longitudinal edges 446 is provided with aflap 452 for properly engaging the other one of the longitudinal edges446 after the thermal insulation jacket 440 is placed around the heatedconduit. Using the flap 452 to close the longitudinal slit 444 helps toreduce heat loss to the outside environment. Preferably, the flap 452 isalso made of a thermal insulation material to provide thermalinsulation. The flap 452 may be made of an adhesive tape, or providedwith an adhesive coating, or alternately may be Velcro® or a flap thatincludes mechanical snaps, among other securing techniques, such thatthe flap 452 is secured to the other one of the longitudinal edges 448and along an outer surface of the tubular insulation body 442.

In each of the thermal insulation jacket embodiments as describedherein, it is preferable that the jackets are extruded. Additionally, itshould be understood that any of the features, e.g., air chambers,pockets sized to the heat trace section geometry, longitudinal slit, andflap, may be provided alone or in combination with each other whileremaining within the scope of the present disclosure. Moreover, multiplepockets may be provided to facilitate multiple heat trace sections 52while not departing from the spirit and scope of the present disclosure.

Referring now to FIGS. 29-31, another form of a modular heater system isillustrated and generally indicated by reference numeral 500. Generally,the modular heater system 500 comprises a heat trace assembly 502 and aconnector assembly 504. Only one (1) heat trace assembly 502 and one (1)connector assembly 504 are shown for purposes of clarity, and it shouldbe understood that the modular heater system 500 can, and often does,include a plurality of either or both heat trace assemblies 502 andconnector assemblies 504, depending on the end application.

The heat trace assembly 502 is adapted for contacting and heating, forexample, a conduit 13 of the semiconductor processing system 10 aspreviously described and shown in FIGS. 1 and 2. It should be understoodthat the modular heater system 500 can be applied to numerous endapplications, and thus the semiconductor processing system 10 asillustrated and described herein is merely exemplary. Accordingly, theseend applications are hereinafter referred to as “target systems” for themodular heater system 500. The connector assembly 504 is also adaptedfor contacting and heating, for example, a joint, connector, or othercomponent of the target system. Additionally, the connector assembly 504secures adjacent heat trace assemblies 502 to each other andaccommodates the joints, connectors, or other components of the targetsystem. The connector assembly also provides both heat to the componentsof the target system and insulation from heat loss to the outsideenvironment, among other functions, as described in greater detailbelow.

Heat Trace Assembly 502

As shown in FIGS. 32 and 33, the heat trace assembly 502 comprises aheat trace section 510, an insulation jacket 512, and terminatingmembers 514. Generally, the insulation jacket 512 is adapted forplacement around the heat trace section 510, and the terminating members514 are adapted for engagement with both the heat trace section 510 andthe insulation jacket 512. The terminating members 514 also provide forthe electrical connections between the heat trace section 510 and theadjacent connector assembly 504 as previously illustrated, or between anadjacent heat trace section 510 and a power source (not shown).Accordingly, lead wires 516 (which are illustrated only partially and asstraight segments for purposes of clarity) exit the terminating members514 to create these adjacent electrical connections.

Referring to FIGS. 34-36, the heat trace section 510 is illustrated andnow described in greater detail. As shown, the heat trace section 510defines an elongated shape and includes a curved portion 520 and a pairof opposed locking edges 522 extending longitudinally along the heattrace section 510. The curved portion 520 defines an inner surface 524that encompasses an open channel 526 for placement around, for example,the conduit 13 as previously illustrated and described in FIGS. 5 and 6.The inner surface 524 is preferably complementary to an outer surface ofthe conduit 13 to improve the heat transfer and the connection betweenthe heat trace section 510 and the conduit 13. The curved portion 520preferably surrounds at least half of the entire outer surface of theconduit 13 to provide more uniform heat transfer and to allow forself-locking of the heat trace section 510 around the conduit 13 by thelocking edges 522. The locking edges 522 function as the previouslyillustrated and described locking edges 58 (FIGS. 7 and 8) and aretherefore not described in further detail hereinafter. Additionally, theheat trace section 510 also comprises conductors 528 as shown, whichfunction as the previously illustrated and described conductors 64(FIGS. 7 and 8) and are similarly not described in further detailhereinafter.

Similar to the previously described heat trace sections 52 (FIGS. 7 and8), the heat trace sections 510 are preferably preformed in sizescorresponding to different sizes, or outside peripheries of, forexample, the conduit 13. The heat trace sections 510 are preferablyextruded and are also capable of being cut to length, according to adesired length for a particular section of conduit 13. Preferably, theheat trace sections 510 are provided in standard sizes and lengths forease of repair and replacement within a conduit system such as thesemiconductor processing system 10 as previously illustrated anddescribed. Accordingly, the modular construction of the heater systemaccording to the teachings of the present disclosure facilitates arelatively low cost heater system that is easily adapted to, forexample, a conduit system.

As further shown, the heat trace section 510 preferably comprises asemiconductive polymer core 530 surrounded by a dielectric cover 532.Although not illustrated, the heat trace section 510 may also compriseoptional materials for a ground plane and an outer cover, among otherfunctional materials, as previously described. Additionally, thedielectric cover 532 is preferably co-extruded with the semiconductivepolymer core 530, however, the dielectric cover 532 may alternately beseparately formed and adapted for placement around the semiconductivepolymer core 530 in a post-assembly process.

Advantageously, the heat trace section 510 defines a plurality ofinsulation stand-offs, preferably in the form of fins 540 as shown, thatextend from an outer surface 542 of the dielectric cover 532 and thelocking edges 522, preferably in a normal direction as shown, towards aninterior surface 513 of the insulation jacket 512. The fins 540preferably taper as shown from a root section 544 to a tip section 546and define passageways 548 between the plurality of fins 540 and theinsulation jacket 512. When the heat trace section 510 is assembledwithin the insulation jacket 512 as shown in FIG. 36, these passageways548 provide insulation, in the form of air as shown, such that heat lossfrom the heat trace section 510 to the outside environment duringoperation is further reduced. Additionally, the improved insulationeffect provides for a “touch-safe” temperature on the outside of theinsulation jacket 512 such that the heat trace assembly 502 can becontacted by a user during operation of the modular heater system 500.

It should be understood that any number of fins 540, along withdifferent geometrical configurations of the fins 540 other than thetapering geometry as shown, may be employed while remaining within thescope of the present disclosure. For example, as shown in FIG. 35,angled fins 540′ (shown dashed) may be employed to provide a “wiping”action against the interior surface 513 of the insulation jacket 512,resulting in passageways 548 that have an improved seal from adjacentpassageways 548. Moreover, other geometrical configurations such as an“S” or a “Z” for the cross-sectional shape, rather than or in additionto the fins 540, may also be employed while remaining within the scopeof the present disclosure. The passageways 548 may alternately be filledwith an insulating material such as a foam, or a polyimide foam, amongother forms of materials rather than employing air as illustrated anddescribed herein while remaining within the scope of the presentdisclosure.

Referring now to FIGS. 37 and 38, the insulation jacket 512 isillustrated and now described in greater detail. As shown, theinsulation jacket 512 preferably comprises two (2) segments 550 and 552,which are preferably symmetrical such that the same segment can be usedfor the assembled insulation jacket 512, and as such, the segments 550and 552 are interchangeable. Each segment 550 and 552 defines a shapethat is compatible with the heat trace section 510 as previouslydescribed, i.e. circular in the embodiment illustrated herein. Thesegments 550 and 552 further comprise chambers 554 extendinglongitudinally between an outer wall 556 and an inner wall 558, whichare separated by supports 559. The chambers 554 provide insulation, inthe form of air as shown, such that heat loss from the heat tracesection 510 to the outside environment during operation is furtherreduced. Preferably, the insulation jacket 512 is also extruded andcomprises a semi-rigid polymeric material such as polycarbonate in oneform of the present disclosure. Alternately, the insulation jacket 512may comprise other materials such as those set forth above in connectionwith the alternate thermal insulation jackets shown in FIGS. 24-28.

As further shown, the insulation jacket 512 includes a hinge and snapfeature such that the insulation jacket 512 can be easily installed ontoand removed from the heat trace section 510. More specifically, eachsegment 550 and 552 comprises opposed curved lips 562 and 564 andadjacent opposed locking tabs 566 and 568, respectively, that extendlongitudinally along opposed hinges 570 and 572 of the insulation jacket512. One of the locking tabs 566 is first engaged within an adjacentcurved lip 562, and then the two segments 550 and 552 are rotated abouta longitudinal axis X of the insulation jacket 512 until the opposedlocking tab 568 engages and snaps over the adjacent curved lip 564. Assuch, the insulation jacket 512 is easily installed onto the heat tracesection 510 without the need for additional parts or hardware. To removethe insulation jacket 512, the two segments 550 and 552 are simplyrotated about the longitudinal axis X towards one another such that thelocking tab 568 disengages from the curved lip 564. Accordingly, theinsulation jacket 512 is preferably a resilient and relatively flexiblematerial, such as the semi-rigid polycarbonate as described above, toenable this hinge and snap feature.

In an alternate form, each of the two segments 550 and 552 preferablycomprise recessed outer surfaces 580 proximate the hinges 570 and 572 asshown. The recessed outer surfaces 580 accommodate strips of tape 582,(only one strip of tape 582 is illustrated for purposes of clarity),which provide additional insulation and further secure the two segments550 and 552 together. Preferably, the tape 582 is non-conductive and isa material such polyester or polyimide, by way of example. It should beunderstood that the illustration and description of tape is exemplaryonly and other securing members such as Velcro®, among others, may alsobe employed while remaining within the scope of the present disclosure.

Referring to FIG. 37, at least one of the segments, segment 552 asshown, further comprises slots 584 formed proximate the end portions 586and 588. These slots 584 accommodate features of the terminating members514 shown in FIGS. 32 and 33, which are now described in greater detail.

Referring to FIGS. 39 and 40, the terminating member 514 is adapted forconnection to the heat trace section 510 (and also the insulation jacket52 not shown) and comprises an embossment 590 that provides egress forthe lead wires 516 and also acts as a strain relief for the lead wires516. The embossment 590 is thus configured for placement within the slot584 of the insulation jacket 512 as previously illustrated anddescribed. As further shown, the embossment 590 comprises adjacent lands592 and 594, which are separated by a groove 596, wherein the groove 596provides a dielectric standoff between the two lead wires 516 thategress through passageways (not shown) in the adjacent lands 592 and594. Preferably, the embossment 590 is integrally formed with theterminating member 514, and the terminating member 514 is preferably aninsulating material such as polymer or a fluoropolymer, by way ofexample.

In one form of the present disclosure, the terminating member 514comprises a housing body 600 and an end cap 602 that is secured to thehousing body 600. Generally, the end cap 602 is provided to cover andinsulate an interior portion of the housing body 600 that houseselectrical connections as described in greater detail below. Morespecifically, and with reference to FIGS. 41-43, the end cap 602comprises resilient arms 604 and 606 that include locking extensions 608and 610, respectively, at their end portions as shown. Correspondingly,the housing body 600 comprises grooves 612 and 614 that accommodate theresilient arms 604 and 606 and a face 616 that is engaged by the lockingextensions 608 and 610. As the end cap 602 is slid onto the housing body600, wherein the resilient arms 604 and 606 progressively slide alongthe grooves 612 and 614, the resilient arms 604 and 606 are deflectedoutwardly. As the locking extensions 608 and 610 then progress past thegrooves 612 and 614, the resilient arms 604 and 606 deflect backinwardly and the locking extensions 608 and 610 engage the face 616 ofthe housing body 600 to secure the end cap 602 to the housing body 600.Although the resilient arms 604 and 606 are illustrated and described asengaging the exterior of the housing body 600, it should be understoodthat the resilient arms 604 may alternately be disposed against theinterior of the housing body 600 while remaining within the scope of thepresent disclosure.

Additionally, the end cap 602 comprises flanges 620 and 622 that aresized to fit over corresponding inner profile surfaces 624 and 626 ofthe housing body 600. These flanges 620 and 622 primarily function asadditional dielectric for the overall terminating member 514 while alsoproviding an improved aesthetic appearance by eliminating anyline-of-sight to the electrical connections inside the terminatingmember 514. In this regard, the housing body 600 further comprises walls627 and 628 that extend rearwardly from the face 616, which also providedielectric standoff for the electrical connections. It should beunderstood that the specific shape and position of the flanges 620 and622 as dielectric extensions are exemplary only, and other shapes andpositions of such dielectric extensions of the end cap 602, amongdielectric extensions for other components (e.g., housing body 600), maybe employed while remaining within the scope of the present disclosure.

Referring now to FIGS. 44-46, and also to FIG. 42, the back side of thehousing body 600 comprises interior cavities 630 and 632 and a set ofupper apertures 634 and 636, along with a set of lower apertures 638 and640, to accommodate the electrical connections. Generally, the leadwires 516 extend through the embossment 590, through the upper apertures634 and 636, and into the interior cavities 630 and 632. Extension wires650 and 652 are connected to the conductors 528 of the heat tracesection 510 (not shown) and also extend into the interior cavities 630and 632. The lead wires 516 are then preferably connected to theextension wires 650 and 652 with crimps 654 and 656 as shown.Accordingly, the electrical connections between the lead wires 516 andthe heat trace section 510 are disposed within the cavities 630 and 632,and dielectric protection is provided by the walls 627 and 628 of thehousing body 600.

Referring back to FIGS. 39 and 41, and also to FIGS. 46-47, the frontside of the housing body 600 comprises a plurality of outer extensions660 separated by slots 662. The outer extensions 660 are adapted forplacement around the heat trace section 510, and more specifically,engage the outer surfaces 542 of the heat trace section 510. Preferably,the outer extensions 660 are designed with a slight draft angle suchthat they provide a positive engaging force against the outer surfaces542 of the heat trace section 510. The outer extensions 660 alsofunction to provide additional dielectric separation between the heattrace section 510 and the outside environment. The fins 540 of the heattrace section 510 are then nested within the slots 662 as shown and abutthe face 616 of the terminating member 514 in the fully assembledcondition. To further facilitate such nesting, the outer extensions 660preferably comprise angled faces 664 as shown to provide more intimatecontact between the outer extensions 660 and the fins 540.

The housing body 600 further comprises a profiled inner extension 670that defines an arcuate upper portion 672 and lower sections 674 and676. The profiled inner extension 670 engages the inner surface 524 ofthe heat trace section 510 as shown, which further secures the heattrace section 510 to the terminating member 514. The profiled innerextension 670 also functions to provide additional dielectric separationsimilar to the outer extensions 660. Preferably, the arcuate upperportion 672 defines a tapering cross section from a thicker portion atthe face 616 to a thinner end portion 678 as shown. The thinner endportion 678 thus facilitates easier assembly of the heat trace section510 and the terminating member 514. Additionally, the lower sections 674and 676 are configured to engage outer surfaces of the fins 540 asshown.

Connector Assembly 504

Referring now to FIGS. 48-50, the connector assembly 504 comprises ashell 700, which preferably includes a plurality of shell members 702and 704. The shell members 702 and 704 are preferably interchangeablesuch that they are used for both the upper portion 706 of the shell 700and the lower portion 708 of the shell 700 as shown. Together, the shellmembers 702 and 704 define outer rims 710 and 712, respectively, whereinthe rims 710 and 712 are adapted for placement over the heat traceassembly 502 as shown in FIG. 30. These rims 710 and 712 provideadditional thermal isolation and reduce the line-of-sight into theconnections within the modular heater system 500 for improvedaesthetics. Additionally, upper rim 714 and lower rim 716 are formedaround the shell members 702 and 704, respectively, which are alsoadapted for placement over another heat trace assembly 502. Similarly,the upper rim 714 and the lower rim 716 provide additional thermalisolation and reduce the line-of-sight into the connections within theconnector assembly 504 for improved aesthetics.

The shell members 702 and 704 also comprise an outer wall 720 and aninner wall 722 that define cavities 724 separated by supports 726. Thecavities 724 provide additional insulation to reduce heat losses to theoutside environment and also provide for a touch-safe temperature on theexterior of the shell 700. The shell members 702 and 704 in generalcomprise a plurality of outer and inner walls as shown to define variouscavities for the purposes of insulation, dielectric separation, andtouch-safe temperatures. Accordingly, these additional walls andcavities as shown are not described in greater detail hereinafter forpurposes of clarity.

Additionally, the shell members 702 and 704 comprise hinge elements 730and flexible tabs 732 that engage detents 734 as shown. As such, theupper portion 706 and the lower portion 708 are rotatable about thehinge elements 730, and the flexible tabs 732 disposed at the endportions of the outer rims 710 engage the detents 734 disposed at theend portions of the other outer rims 712 to lock the shell portions 706and 708 together. Preferably, the outer rims 710 and 712 are sized toprovide a positive engaging force on the outside of the heat traceassembly 502.

As further shown, the shell members 704 include additional retainingfeatures such as flexible tabs 740 that engage openings 742 formedthrough the inner walls 722 of the shell members 702. Accordingly, theflexible tabs 740 and the openings 742 provide a more secure connectionbetween adjacent shell members 702 and 704. Additionally, the shellmembers 702 comprise outer wall extensions 746 that engage correspondingouter wall recesses 748 of the shell members 704 as shown. Accordingly,the outer wall extensions 746 and the corresponding outer wall recesses748 provide both alignment of the shell members 702 and 704 forassembly, in addition to thermal separation and reduced line-of-sightfor improved aesthetics. The shell members 702 and 704 are preferably aninsulative material and are preferably molded from a higher temperaturematerial such as a thermoplastic polymer. However, it should beunderstood that other materials and processing methods may be employedwhile remaining within the scope of the present disclosure.

Disposed inside the shell 700 are additional components of the connectorassembly 504, including a fitting heater assembly 750, which is bestshown in FIGS. 50-52. The fitting heater assembly 750 comprises afitting adapter 752, a heat trace section 754, and an outer casing 756that is preferably in two (2) pieces as shown. The fitting adapter 752defines an opening 760 that is sized to mate with an adjacent fitting orcomponent of the target system (not shown). Accordingly, it should beunderstood that the size and shape of the opening 760 as illustrated anddescribed herein is merely exemplary and should not be construed aslimiting the scope of the present disclosure.

The fitting adapter 752 also defines a recessed outer periphery 762having grooves 764, both of which are sized to accommodate the geometryof the heat trace section 754 as shown. Preferably, the fitting adapter752 is a conductive material such as Aluminum, however, other materialsmay also be used while remaining within the scope of the presentdisclosure. Alternately, the fitting adapter 752 may include slits 768(shown dashed) to provide for expansion of the opening 760 and thus moreintimate contact with the adjacent fitting of the target system.

Preferably, the outer casing 756 is provided in symmetrical,interchangeable pieces as shown. The outer casings 756 include outerwalls 770 and inner walls 772 that define conduits 774 therebetween. Theconduits 774 provide a passageway for the lead wires (not shown) toconnect to the heat trace section 754. The outer casings 756 alsoinclude hinge elements 776 that cooperate with the hinge elements 730 ofthe shell members 702 and 704, which are also shown in FIG. 49. As such,the hinge elements 776 preferably include pins 778 that are adapted forplacement within holes 731 (FIG. 50) of the shell member hinge elements730. Additionally, the conduits 774 extend through the hinge elements776 as shown to provide egress for the lead wires that connect to theheat trace section 754. Preferably, the hinge elements 776 are disposedon an extension 779 as shown, wherein the extension 779 functions as astrain relief for the lead wires.

The outer casings 756 also preferably include standoffs 780 extendingfrom their outer faces 782 as shown. These standoffs 780 function tocenter, or position, the fitting heater assembly 750 properly within theshell 700.

In an alternate form of the outer casings 756, as illustrated in FIG.53, a snap feature is employed to securely connect each of the two outercasings 756 to each other. (Only one outer casing 756 is shown forpurposes of clarity). More specifically, the casing 756 comprisesflexible latches 780 that extend from a boss 781, both of which arepreferably integrally formed with the outer casing 756. The flexiblelatches 780 define tapered end portions 782 that include relatively flattransverse faces 783 as shown. As further shown, a bore 784 is formedthrough an opposing boss 785, which is also preferably integrally formedwith the outer casing 756. A counterbore 786 (shown dashed) is alsoformed in the opposing boss 785, which defines an internal shoulder 787(shown dashed). As the tapered end portions 782 engage the bore 784 ofan opposing outer casing 756 (not shown), the flexible latches 780deflect inwardly, towards each other such that the flexible latches 780and the tapered end portions 782 can traverse the length of the bore784. As the tapered end portions 782 enter the counterbore 786, theflexible latches 780 deflect back outwardly, and the transverse faces783 engage the internal shoulder 787 to secure the outer casings 756together. To separate the two outer casings 756, the flexible latches780 are deflected inwardly through the counterbore 786 until thetransverse faces 783 clear the internal shoulder 787, and the two outercasings 756 can then be pulled apart. It should be understood that thisconnecting device is exemplary only and thus other connecting devicesfor the outer casings 756 may also be employed while remaining withinthe scope of the present disclosure.

Referring now to FIGS. 49-50 and 54-55, the connector assembly 504 mayalso be provided with a cover 800 if the connection is in an elbowconfiguration as shown or in a T-configuration (not shown), wherein anadjacent heat trace assembly 502 is not disposed in one side of theconnector assembly 504. Accordingly, the cover 800 provides additionaldielectric separation between the fitting heater assembly 750 and theoutside environment, while also providing for a touch-safe surfacetemperature and improved aesthetics. As shown more clearly in FIGS. 53and 54, the cover 800 includes an outer wall 802 and an inner wall 804that define gaps 806 therebetween for insulation purposes and thedielectric isolation. The cover 800 further comprises flexible clips 808that are adapted for placement over an outer wall 810 of the shellmember 702 to secure the cover 800 to the overall connector assembly504.

It should be understood that the exemplary connector assembly 504 asillustrated and described herein is configured for an elbow-typeconnection within the target system and that the geometry and featuresof the connector assembly 504 and its various components will varydepending on the connection employed within the target system. Forexample, if the connector assembly 540 were adapted for placement over aT-junction or a cross-type junction, or even a separate component suchas a pump, by way of example, the size and shape of the connectorassembly 540 components would be adjusted accordingly. Therefore, thespecific design of the connector assembly 540 as illustrated anddescribed herein should not be construed as limiting the scope of thepresent disclosure.

In another form of the present disclosure, the heat trace assemblies 502are “matched” with the connector assemblies 504 to achieve eventemperatures across their interfaces. More specifically, different powerdensities may be required at the connector assemblies 504 versus theheat traces assemblies 502, and as such, different power densities arecontemplated for each.

In yet another form, a reflective surface coating may be provided alongthe interior surfaces 513 of the insulation jacket 512 and/or the shellmembers 702 and 704 to reduce the power required and also to reduce theexterior surface temperatures of the modular heater system 500components. Such a reflective surface coating preferably has lowemissivity and may include, by way of example, an Aluminum foil or otherlow emissivity material applied by a vapor deposition process, by way ofexample. Similarly, a high emissivity material may be applied betweenthe conduit 13 and the dielectric or insulator material 26, or cover,that surrounds the semiconductive polymer material 24, or conductivecore, of the heat trace section 510. (See FIGS. 3 and 4 for basicconstruction of heat trace section and its terminology). As such, thehigh emissivity material would improve heat transfer between the heattrace section 510 and the conduit 13.

Referring now to FIGS. 56-58, another form of a heat trace assembly isillustrated and generally indicated by reference numeral 820. The heattrace assembly 820 generally includes a heat trace section 822surrounded by an insulation jacket 824, along with the terminatingmembers and connector assemblies as previously described, which are notshown for purposes of clarity. In this alternate form of the presentdisclosure, standoffs 826 are incorporated into the insulation jacket824 rather than into the heat trace section 822 as previouslyillustrated and described. As shown, the standoffs 826 are preferably inthe form of fins, however, it should be understood that other geometriesand configurations may be employed while remaining within the scope ofthe present disclosure, examples of which are described in greaterdetail below. The standoffs 826 preferably extend radially from an innersurface 828 of the insulation jacket 824 to a location proximate thedielectric cover 830 that surrounds the semiconductive polymer core 832of the heat trace section 822, thereby forming passageways 827 betweenthe insulation jacket 824 and the heat trace section 822. Preferably,the distal end portion 834 of the standoffs 826 are in physical contactwith the heat trace section 822 such that the standoffs 826concentrically position the heat trace section 822 within the insulationjacket 824. As such, the position and shape of the distal end portions834 of the standoffs 826 are compatible with the shape and/or size ofthe heat trace section 822, which may be other than circular asillustrated herein.

In addition to the standoffs 826, the insulation jacket 824 furthercomprises chambers 836 that extend longitudinally between an outer wall838 and an inner wall 840, which are separated by supports 842. Thesupports 842 are formed conjointly with the standoffs 826 as shown,however, the supports 842 and standoffs 826 may be located in separatelocations around the insulation jacket 824 while remaining within thescope of the present disclosure. As previously described, the chambers836 provide insulation, in the form of air as shown, such that heat lossfrom the heat trace section 822 to the outside environment duringoperation is reduced. Additionally, the chambers 836 and/or the spacebetween the heat trace section 822 and the insulation jacket 824,between the standoffs 826, may be filled with an insulating materialsuch as a foam or alternately a low emissivity material as previouslydescribed.

Preferably, the insulation jacket 824 is formed as a single, unitarypiece, yet remains flexible in order to be installed around the heattrace section 822. Accordingly, the insulation jacket 824 comprises areduced area 850 that is formed opposite a lip 852 and a locking tab854. The reduced area 850 is preferably formed through a thicker wallsection 856 of the insulation jacket 824 and defines an outer recess858, a web portion 860, and an inner recess 862. The reduced area 850thus divides the insulation jacket 824 into a first segment 864 and asecond segment 866. The insulation jacket 824 is preferably made from asemi-rigid polymeric material, such as polycarbonate as previously setforth, and as such the reduced area 850, and more specifically the webportion 860, provides a “living hinge” such that the first segment 864and the second segment 866 are rotatable about the reduced area 850. Asthe first segment 864 and the second segment 866 are rotated towards oneanother, the locking tab 854 engages the lip 852 as shown in order tosecure the insulation jacket 824 around the heat trace section 822. As aresult, the insulation jacket 824 is advantageously provided as asingle, unitary piece, rather than in multiple pieces as previouslyillustrated and described. Moreover, multiple reduced areas 850 may beemployed around the insulation jacket 824 rather than the single reducedarea 850 while remaining within the scope of the present disclosure.

Referring to FIGS. 59 a and 59 b, alternate forms of insulationstandoffs are illustrated and generally indicated by reference numeral870. As shown, the insulation standoffs 870 extend circumferentiallyaround the insulation jacket 824 rather than longitudinally aspreviously illustrated and described, and as such, take the form of“rings” in this illustrative structure of the present disclosure. Thestandoffs 870 may be continuous and evenly spaced as shown in FIG. 59 a,or discontinuous and alternately spaced as shown in FIG. 59 b, by way ofexample, along the length of the insulation jacket 824. Additionally,the standoffs 870 may be of different lengths and geometricconfigurations, and still yet may be formed as a part of the heat tracesection 822 (not shown) rather than as a part of the insulation jacket824 as shown herein. Moreover, while the circumferential standoffs 870are preferably formed as an integral part of the insulation jacket 824(or the heat trace section 822), the standoffs 870 may be separatepieces that are assembled to the insulation jacket 824 or the heat tracesection 822. For example, as shown in FIG. 59 c, the insulation jacket824 (or the heat trace section 822) may include a plurality of slots 872that receive separate standoffs 870′, which are then interchangeable andcan be varied in number/spacing according to specific applicationrequirements. As such, the standoffs 870′ include protrusions 874 thatare sized to fit and be secured within the slots 872 as shown. Theprotrusions 874 are then slidably engaged within the slots 872 to securethe standoffs 870′ in the desired location(s).

Referring back to FIG. 57, the heat trace section 822 includes thedielectric cover 830 that surrounds the semiconductive polymer core 832,along with the pair of conductors 831 extending along the length of theheat trace section 822 for the application of power. In one form of thepresent disclosure, the dielectric cover 830 (in the plurality ofgeometric configurations as illustrated and described herein) ispreferably co-extruded (either in one extrusion run or multipleextrusion runs) with the semiconductive polymer core 832. In anotherform, the dielectric cover 830 is separately formed and is slidablyengaged around the semiconductive polymer core 832. In still anotherform, the dielectric cover 830 is applied to the semiconductive polymercore 832 by means of painting, spraying, dip coating, taping, heatshrinking, or other similar application methods rather than being aseparate component that is slid onto the semiconductive polymer core832. Still further yet, the dielectric cover 830 can alternately beapplied by these means to the actual conduit 13 (see, e.g., FIGS. 5-8)rather than or in addition to being applied over the semiconductivepolymer core 832. For applications that are relatively low temperatureand thus may not require thermal insulation, the dielectric cover 830can be eliminated altogether from the heat trace section 822 such thatonly the semiconductive polymer core 832 and the conductors 831 form theheat trace section 822. Accordingly, the heat trace section 822 may beformed without any dielectric cover 830 in certain applications. Itshould be understood that such variations are considered to be withinthe scope of the present disclosure.

Referring now to FIGS. 60 and 61, another form of a heat trace assemblyis illustrated and generally indicated by reference numeral 880. Theheat trace assembly 880 comprises a carrier 882 that is adapted forplacement around the conduit 13, and a heat trace section 884 secured tothe carrier 882. In this embodiment, a standard/conventional heat tracesection 884 can be employed without forming the heat trace section 884to the shape of the conduit 13 as previously illustrated and described.Accordingly, the carrier 882 comprises an interior surface 886 thatdefines a shape complementary to the conduit 13, along with extensions887 that extend around at least one half of the periphery of the conduit13 as shown. The carrier 882 further comprises a recessed upper surface888 that is sized to receive the heat trace section 884. The heat tracesection 884 is then secured within this recessed upper surface 888 byany of a variety of means. For example, the heat trace section 884 maybe press-fit or snapped into the recessed upper surface 888, the carrier882 may include a feature to secure the heat trace section 884, anadditional component (e.g. retaining clip) may be used to secure theheat trace section 884 to the carrier 882, or an adhesive may be used tosecure the heat trace section 888 within the carrier 882, among otherfastening or securing methods. Preferably, the carrier 882 is made of amaterial such as aluminum, brass, copper, or a conductive polymer sothat the heat generated from the heat trace section 884 can beefficiently transferred to the conduit 13. It should be understood thatthe insulation jackets as previously illustrated and described hereinmay also be employed with this heat trace assembly 880 while remainingwithin the scope of the present disclosure, even though such insulationjackets are not explicitly illustrated and described with thisembodiment.

Referring to FIGS. 62 a and 62 b, alternate forms of the carrier areillustrated and generally indicated by reference numerals 882 a and 882b, respectively. As shown in FIG. 62 a, the carrier 882 a defines arecessed upper surface 888 a that defines a curved geometry toaccommodate a corresponding curved heat trace section 884 a. The curvedgeometry thus provides for improved heat transfer from the heat tracesection 884 a to the conduit 13 since the heat trace section 884 agenerally follows the contour of the underlying conduit 13. As shown inFIG. 62 b, the carrier 882 b defines multiple recessed upper surfaces888 b, which may be curved as shown or relatively straight or flat aspreviously illustrated in FIGS. 60 and 61. As such, the carrier 882 b ispreferably employed in applications where the conduit 13 has arelatively large size and requires multiple heat trace sections 884 b tosufficiently surround the conduit 13.

In one form, the carrier 882 is preferably an aluminum extrusion,however, other materials that sufficiently transfer heat from the heattrace section 884 to the conduit 13 may also be employed while remainingwithin the scope of the present disclosure. For example, the carrier 882may alternately be a polymer material. Additionally, alternatemanufacturing methods other than extrusion, e.g., machining, may also beemployed while remaining within the scope of the present disclosure.

Referring now to FIGS. 63 through 65, a form of a heat trace sectionhaving an alternate end termination is illustrated and generallyindicated by reference numeral 900. The heat trace section 900 comprisesa stripped end portion 902, wherein a portion of the dielectric cover904 and the conductive core 906 have been stripped back such that thepair of conductors 908 and an inner wall 912 of the dielectric cover 904are exposed as shown. The terminating member 910 is then slid onto theheat trace section 900 as shown, such that the inner wall 912 of theheat trace section 900 provides additional dielectric separation betweenthe components housed within the terminating member 910, (e.g. leadwires 914, conductive core 906, and barrel-crimp connections 916), andthe conduit 13, in addition to eliminating any line-of-sight to theelectrical connections inside the terminating member 910. Theterminating member 910 also includes features as shown such that theouter surfaces of the heat trace section 900 are covered or overlappedby such features to provide dielectric separation and to reduce anyline-of-sight as previously described. Additionally, an end cap 918 issecured to the terminating member 910 as shown, similar to the end capsas previously illustrated and described.

In another end termination embodiment as shown in FIGS. 66 through 69, aheat trace section having an alternate end termination is illustratedand generally indicated by reference numeral 920. The heat trace section920 comprises a stripped end portion 922, wherein a portion thedielectric cover 924 and the conductive core 926 have been stripped backsuch that only the pair of conductors 928 extend from the stripped endportion 922 of the heat trace section 920. As further shown, an endshield 932 is placed over the stripped end portion 922 of the heat tracesection 920, wherein the pair of conductors 928 extend through guides934 of the end shield 932. Generally, the end shield 932 is employed toprovide additional dielectric and to reduce line-of-sight to the conduit13. The terminating member 936 is then secured against the end shield932 and accommodates the lead wires and electrical connections aspreviously described. Additionally, an end cap 938 is secured to theterminating member 936 as shown, similar to the end caps as previouslyillustrated and described.

Turning now to FIG. 70, an alternate form of a heat trace assembly isillustrated and generally indicated by reference numeral 940. The heattrace assembly 940 comprises a conductive core 942 and a pair ofconductors 944 disposed therein, similar to the constructions aspreviously described, however, a multi-pieced dielectric cover isemployed around the conductive core 942 as shown. In this illustrativeembodiment, the multi-pieced dielectric cover comprises an inner cover943 and an outer cover 946, each of which comprise curved end portions948 and 950, respectively. The curved end portions 948 and 950 overlapeach other and extend around the conductors 944 and conductive core 942as shown, in order to secure the multi-pieced dielectric cover to theconductive core 942. Both the inner cover 943 and the outer cover 946are preferably separately formed from the conductive core 942 and itsconductors 944, and are thus not co-extruded. Rather than the curved endportions 948 and 950, the covers may be heat sealed, welded, adhesivelybonded, or secured to each other by any number of other known methods.For example, as shown in FIG. 71, an inner cover 943′ includes standoffs945, and an outer cover 946′ is secured to the standoffs 945 by any ofthese methods along the interfaces 954.

As shown in FIG. 72, a heat trace section comprising a “living hinge” aspreviously set forth in relation to the insulation jacket is illustratedand generally indicated by reference numeral 960. The heat trace section960 comprises a reduced area 962 as shown, which includes an outerrecess 964, a web portion 966, and an inner recess 968. The reduced area962 thus divides the heat trace section 960 into a first segment 970 anda second segment 972. Accordingly, the reduced area 962, and morespecifically the web portion 966, provides a “living hinge” such thatthe first segment 970 and the second segment 972 are rotatable about thereduced area 962. As a result, the heat trace section 960 in thisalternate form can be installed onto a conduit (not shown) more easily.Additionally, it should be understood that multiple reduced areas 962may be employed around the heat trace section 960 rather than the singlereduced area 962 while remaining within the scope of the presentdisclosure.

Referring now to FIGS. 73 and 74, an alternate form of a fitting adapter(previously illustrated and described in an alternate form as referencenumeral 52 in FIGS. 50-52) is illustrated and generally indicated byreference numeral 980. The fitting adapter 980 comprises an opening 982that is sized to mate with an adjacent fitting 983 as shown, along witha recessed outer periphery 984 to accommodate the heat trace section 754(not shown) as previously illustrated and described. The fitting adapter980 comprises extensions 986 and 988, which extend along a portion ofthe conduit (not shown) that is secured to the adjacent fitting 983.Alternately, the extensions 986 and 988 are positioned along entiresections of conduit that may be relatively short and thus would besomewhat difficult to fit with a heat trace assembly as previouslyillustrated and described herein. As such, the extensions 986 and 988 ofthe fitting adapter 980 are capable of distributing heat to theunderlying portions of conduit from the heat trace section 754 (notshown) that is disposed within the recessed outer periphery 984.Therefore, no separate heat generating element (i.e. heat traceassembly) is required in certain sections of the conduit with the use ofthe heat distributing extensions 986 and 988. It should be understoodthat more or less than two extensions 986 and 988 may be employed andthat the extensions 986 and 988 may be of differing lengths andgeometries while remaining within the scope of the present disclosure.

As further shown, the fitting adapter 980 comprises internal grooves990, which are adapted to accommodate adjacent sections of heat traceassemblies as previously illustrated and described. Additionally, itshould be understood that the shape of the opening 982 is alteredaccording to the shape of the adjacent fitting being inserted therein,and thus the rectangular shape as illustrated and described hereinshould not be construed as limiting the scope of the present disclosure.

Referring to FIGS. 75 and 76, yet another form of an insulation jacketis illustrated and generally indicated by reference numeral 1000. Asshown, the insulation jacket 1000 comprises a first section 1002 and asecond section 1004 positioned opposite the first section 1002, whichare joined together by a hinge 1020. The hinge 1020 is preferablyco-extruded with the first section 1002 and the section 1004, thusforming a single unitary body for the insulation jacket 1000. The hinge1020 is preferably flush with outer surfaces 1022 and 1024 of the firstand second sections 1002 and 1004, respectively, and rests on first andsecond extensions 1030 and 1032 as shown. Accordingly, the hinge 1020 isformed of a resilient material such that the first and second sections1002 and 1004, respectively, can be rotated relative to each other forinstallation and removal.

As further shown, the first section 1002 includes an open end portion1006 defining a recess 1008, and the second section 1004 includes adetent 1010, which engages the recess 1008 of the first section 1002 asshown. The detent 1010 engages the recess 1008 to secure the firstsection 1002 to the second section 1004, thus securing the insulationjacket 1000 around the heat trace section (not shown) through aconnection that can be readily engaged for installation and disengagedfor removal.

In other forms of the present disclosure, various “indication” means arecontemplated, wherein the state or condition of the heater system isindicated and can be monitored from the outside environment. Forexample, light emitting diodes (LEDs) may be placed along the heat traceassemblies at strategic locations to indicate whether or not the systemis operational. The LEDs may be placed within individual sections of theheat trace assemblies or alternately in various electrical connectionswithin the system. As another example, thermochromic coatings may beapplied anywhere along exterior surfaces of the system, e.g., heat traceassemblies, connector assemblies, to indicate the temperature of thesystem at a certain location. Alternately, thermochromic additives maybe employed within certain resin systems for use within, by way ofexample, the insulating jackets. Moreover, discrete temperature sensorsmay be employed within the system for temperature indications at desiredlocations, along with using the temperature sensors for temperaturecontrol. It should be understood that these various “indication” meansare contemplated to be within the scope of the present disclosure.

The description of the disclosure is merely exemplary in nature and,thus, variations that do not depart from the gist of the disclosure areintended to be within the scope of the disclosure. For example, theconductive polymer material used for the heat trace sections may be asemi-conductive material in order to self-regulate temperature or anon-semi-conductive material such that temperature is not regulatedthrough the material but rather through a control system. Additionally,the thermal insulation jackets may be fitted with an external shell,e.g. rigid plastic, of any shape or geometry, in order to protect thethermal insulation jackets from damage from the outside environment.Such variations are not to be regarded as a departure from the spiritand scope of the disclosure.

1. A heat trace assembly comprising: a heat trace section comprising: apair of bus-conductors; a semiconductive polymer material surroundingthe bus-conductors and functioning as a heating element; a dielectricmaterial surrounding the semiconductive polymer material; and an outerinsulating jacket surrounding the dielectric material; an insulationjacket surrounding the heat trace section; a plurality of standoffsdisposed between the heat trace section and the insulation jacket; and acorresponding plurality of passageways formed between the heat tracesection and the insulation jacket and between the plurality ofstandoffs.
 2. The heat trace assembly according to claim 1, wherein thestandoffs are integrally formed with the insulation jacket.
 3. The heattrace assembly according to claim 1, wherein the standoffs areintegrally formed with the heat trace section.
 4. The heat traceassembly according to claim 1, wherein the standoffs are separate piecesthat are assembled to the insulation jacket.
 5. The heat trace assemblyaccording to claim 1, wherein the standoffs are separate pieces that areassembled to the heat trace section.
 6. The heat trace assemblyaccording to claim 1, wherein the standoffs are fins.
 7. The heat traceassembly according to claim 1, wherein the standoffs are a part of theinsulation jacket and define a distal end portion, and the distal endportion physically contacts the heat trace section to concentricallyposition the heat trace section within the insulation jacket.
 8. Theheat trace assembly according to claim 1, wherein the plurality ofpassageways are filled with a material selected from the groupconsisting of an insulating material and a low emissivity material. 9.The heat trace assembly according to claim 1, wherein the insulationjacket further comprises a plurality of chambers that extendlongitudinally between an outer wall and an inner wall of the insulationjacket.
 10. The heat trace assembly according to claim 9, wherein theplurality of chambers are filled with a material selected from the groupconsisting of an insulating material and a low emissivity material. 11.An insulation jacket for use in a heating system having at least oneheat trace section, the heat trace section comprising a pair ofbus-conductors, a semiconductive polymer material surrounding thebus-conductors and functioning as a heating element, a dielectricmaterial surrounding the semiconductive polymer material, and an outerinsulating jacket surrounding the dielectric material, the insulationjacket comprising a plurality of standoffs extending from an innersurface of the insulation jacket and inwardly towards the heat tracesection, wherein a plurality of passageways are formed between the heattrace section and the insulation jacket and between the plurality ofstandoffs.
 12. The insulation jacket according to claim 11, wherein thestandoffs are integrally formed with the insulation jacket.
 13. Theinsulation jacket according to claim 11, wherein the standoffs areseparate pieces that are assembled to the insulation jacket.
 14. Theinsulation jacket according to claim 11 further comprising a pluralityof segments and at least one reduced area disposed between the segments,wherein the reduced area allows the segments to be rotatable about thereduced area.
 15. The insulation jacket according to claim 14, whereinthe segments and the reduced area are integrally formed with theinsulation jacket such that the insulation jacket is a single, unitarypiece.
 16. The insulation jacket according to claim 11, wherein thestandoffs extend longitudinally along the length of the insulationjacket.
 17. The insulation jacket according to claim 11, wherein thestandoffs extend circumferentially around the insulation jacket.
 18. Theinsulation jacket according to claim 11, wherein the standoffs arediscontinuous along the length of the insulation jacket.